Metal-supported anode for solid oxide fuel cell

Abstract

A metal-supported anode for a solid oxide fuel cell is provided that includes a metal substrate having at least one hole formed therein, and an anode material formed on a first surface of the metal substrate. The anode material is also formed within each of the at least one hole. The at least one hole extends from the first surface of the metal substrate to a second surface of the metal substrate opposite the first surface, and the at least one hole has a different size at the first surface of the metal substrate than at the second surface of the metal substrate.

What is claimed is: 
     
       1. A fuel cell anode comprising
 a metal substrate having a plurality of holes formed therein; and 
 an anode material formed on a first surface of the metal substrate and within each of the plurality of holes such that each of the plurality of holes is infiltrated with the anode material, 
 the plurality of holes having a substantially uniform size and being formed at approximately regular intervals on the first surface of the metal substrate, 
 the plurality of holes extending from the first surface of the metal substrate to a second surface of the metal substrate opposite the first surface, and 
 the plurality of holes having a different size at the first surface of the metal substrate than at the second surface of the metal substrate, each of the plurality of holes having a diameter in a range of 5 to 20 micrometers at the first surface. 
 
     
     
       2. The anode according to  claim 1 , wherein
 the anode material comprises pores and has a porosity of 30% to 50%. 
 
     
     
       3. The anode according to  claim 2 , wherein
 the pores are coated with nickel particles. 
 
     
     
       4. The anode according to  claim 1 , wherein
 the metal substrate comprises stainless steel. 
 
     
     
       5. The anode according to  claim 1 , wherein
 the anode material comprises nickel oxide. 
 
     
     
       6. The anode according to  claim 5 , wherein
 the anode material further comprises a solid oxide ceramic material, and the solid oxide ceramic material is scandia ceria stabilized zirconia. 
 
     
     
       7. The anode according to  claim 5 , wherein
 the anode material is NiO—ScCeSZ comprising 40% by volume to 60% by volume of NiO. 
 
     
     
       8. The anode according to  claim 1 , wherein
 the anode material formed on the first surface of the metal substrate has a thickness of 2.5 μm to 15 μm. 
 
     
     
       9. The anode according to  claim 1 , wherein
 each of the plurality of holes has a diameter in a range of 40 to 60 micrometers at the second surface. 
 
     
     
       10. The anode according to  claim 9 , wherein
 each of the plurality of holes is completely filled with the anode material. 
 
     
     
       11. The anode according to  claim 1 , wherein
 each of the plurality of holes has a first opening at the first surface and a second opening at the second surface, and 
 each of the plurality of holes is completely filled with the anode material from the first opening to the second opening. 
 
     
     
       12. The anode according to  claim 1 , wherein
 the anode material comprises a metal oxide and a solid oxide ceramic material. 
 
     
     
       13. A solid oxide fuel cell comprising:
 a cathode comprising a cathode material; 
 an electrolyte comprising a first solid oxide ceramic material; and 
 an anode comprising:
 a metal substrate having a plurality of holes formed therein; and 
 an anode material formed on a first surface of the metal substrate and within each of the plurality of holes such that each of the plurality of holes is infiltrated with the anode material, 
 
 the plurality of holes having a substantially uniform size and being formed at approximately regular intervals on the first surface of the metal substrate, 
 the plurality of holes extending from the first surface of the metal substrate to a second surface of the metal substrate opposite the first surface, and 
 the plurality of holes having a different size at the first surface of the metal substrate than at the second surface of the metal substrate, each of the plurality of holes having a diameter in a range of 5 to 20 micrometers at the first surface. 
 
     
     
       14. The solid oxide fuel cell according to  claim 13 , wherein
 the cathode material sinters at a temperature of 850° C. or less. 
 
     
     
       15. The solid oxide fuel cell according to  claim 13 , wherein
 the anode material comprises pores and has a porosity of 30% to 50%. 
 
     
     
       16. The solid oxide fuel cell according to  claim 15 , wherein
 the pores are coated with nickel particles. 
 
     
     
       17. The solid oxide fuel cell according to  claim 13 , wherein
 the metal substrate comprises stainless steel. 
 
     
     
       18. The solid oxide fuel cell according to  claim 13 , wherein
 the anode material comprises nickel oxide. 
 
     
     
       19. The solid oxide fuel cell according to  claim 13 , wherein
 the anode material comprises a metal oxide and a second solid oxide ceramic material, and the second solid oxide ceramic material and the first solid oxide ceramic material are the same. 
 
     
     
       20. The solid oxide fuel cell according to  claim 13 , wherein
 the anode material formed on the first surface of the metal substrate has a thickness of 2.5 μm to 15 μm. 
 
     
     
       21. The solid oxide fuel cell according to  claim 13 , further comprising
 a porous reforming layer comprising a metal mesh material, the porous reforming layer being joined to the metal substrate at locations where the plurality of holes are not formed. 
 
     
     
       22. The solid oxide fuel cell according to  claim 21 , wherein
 the metal mesh is coated with a catalyst. 
 
     
     
       23. A method of forming a solid oxide fuel cell, the method comprising:
 forming a plurality of holes in a metal substrate; 
 depositing an electrolyte on a first surface of the metal substrate with the plurality of holes formed therein, the electrolyte comprising a solid oxide ceramic material; 
 depositing a cathode on the electrolyte, the cathode comprising a cathode material; and 
 infiltrating the metal substrate, with the plurality of holes formed therein, with an anode material on a second surface of the metal substrate such that a layer of the anode material is formed between the electrolyte and the first surface of the metal substrate and such that the anode material is provided within each of the plurality of holes, the plurality of holes having a substantially uniform size and being formed at approximately regular intervals on the first surface of the metal substrate, 
 the second surface of the metal substrate being opposite the first surface of the metal substrate, 
 the plurality of holes extending from the first surface of the metal substrate to the second surface of the metal substrate, and 
 the plurality of holes having a different size at the first surface of the metal substrate than at the second surface of the metal substrate, each of the plurality of holes having a diameter in a range of 5 to 20 micrometers at the first surface.